Compression-Resistant Thin-Wall Container

This application claims the benefit of U.S. Provisional Patent Application No. 63/643,823, filed May 7, 2024, and entitled “Compression-Resistant This-Wall Container,” the contents of which are incorporated by reference herein in their entirety.

This disclosure is generally related to the field of bottles and containers and, in particular, to compression-resistant thin-wall containers.

Single-use water bottles may be made of recyclable plastics, such as poly (ethylene terephthalate) (PET), yet the majority of plastic bottles are landfilled. Many municipal curbside recycling programs will not accept lightweight disposable plastic water bottles because they are easily flattened, then incorrectly separated with paper materials at Material Recovery Facilities (MRFs), and ultimately contaminate the paper recycling stream. A 2015 Material Flow Study demonstrated that, on average, 15% of PET water bottles and 34% of non-bottle PET containers end up in the paper recycling stream as contamination.

Disclosed is a compression-resistant container that overcomes at least one of the shortcomings described above. In an embodiment, the container incorporates alternating cylinders and spheres across the body of the container. As the container is compressed, the spheres distribute the load across the surfaces, which increases the amount of force that is required to compress the container. This shape makes the container more difficult to flatten during recycling, thereby preventing plastic bottles from commingling with paper during the automated sorting process.

In an embodiment, a compression-resistant container includes a wall at least partially enclosing a volume. A shape of the wall includes a set of spheroidal surfaces having at least a first spheroidal surface and a second spheroidal surface. The shape of the wall further includes a set of cylindrical surfaces having at least a first cylindrical surface, where the first spherical surface adjoins at least the first cylindrical surface and is positioned between the first cylindrical surface and the second cylindrical surface.

In some embodiments, the wall is made from a synthetic resin. In some embodiments, the wall is made from poly(ethylene terephthalate). In some embodiments, a thickness of the wall is between 0.05 mm and 0.5 mm. In some embodiments, at least some surfaces of the set of spheroidal surfaces and the set of cylindrical surfaces are positioned in an alternating pattern along an axis. In some embodiments, a ratio of a diameter of each of the set of spheroidal surfaces to each of the set of cylindrical surfaces is between 1.5:1 and 4:1. In some embodiments, each of the set of spheroidal surfaces has a shell thickness ratio of between 1:500 and 1:200. In some embodiments, a tangential surface angle between each of the set of spheroidal surfaces and each of the set of cylindrical surfaces is between 30 degrees and 80 degrees. In some embodiments, the container has an internal volume between 10 mL and 10 L. In some embodiments, the mass of the container is between 0.05 g and 2 kg.

In an embodiment, such as in the case of a bottle, the wall has rotational symmetry around an axis, where the set of spheroidal surfaces corresponds to a set of spheroidal segment shells having at least a first spheroidal segment shell corresponding to the first spheroidal surface and a second spheroidal segment shell corresponding to the second spheroidal surface, each spheroidal segment shell of the set of spheroidal segment shells having rotational symmetry around the axis, and where the set of cylinder surfaces corresponds to a set of cylinder shells having at least a first cylinder shell corresponding to the first cylinder surface, each cylinder shell of the set of cylinder shells having rotational symmetry around the axis, and where the first cylinder shell is positioned between the first spheroidal segment shell and the second spheroidal segment shell.

In some embodiments, the set of spheroidal segment shells and the set of cylinder shells define at least a portion of a body of the shape of the wall, and the shape of the wall further comprises a neck and a base. In some embodiments, the base has a diameter between 4 mm and 1000 mm. In some embodiments, the base has a length between 4 mm and 1000 mm. In some embodiments, a total length of the container is between 20 mm and 2000 mm. In some embodiments, the set of spheroidal segment shells further includes a third spheroidal segment shell, the set of cylinder segment shells further includes a second cylinder segment shell and a third cylinder segment shell, where the second cylinder segment shell is between the first spheroidal segment shell and the second spheroidal segment shell, and where the third cylinder segment shell is between the second spheroidal segment shell and the third spheroidal segment shell.

In an embodiment, such as in the case of a box or clamshell, the set of spheroidal surfaces and the set of cylindrical surfaces define at least a portion of a body, and the body defines a container shape. In some embodiments, the set of spheroidal surfaces further includes a third spherical surface and a fourth spherical surface, the set of cylindrical surfaces further includes a second cylindrical surface and a third cylindrical surface, where the set of spheroidal surfaces alternate with the set of cylindrical surfaces with the second spheroidal surface positioned between the second cylindrical surface and the third cylindrical surface and the third spheroidal surface positioned between the third and fourth cylindrical surface. In some embodiments, the container includes a hinged opening between a top of the body and a bottom of the body. In some embodiments, the container is a box, a clamshell, or other container for food.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the disclosure.

Referring to, an embodiment of a compression-resistant containeris depicted. The compression-resistant containermay include a wall. The wallmay be made from a synthetic resin and/or from poly(ethylene terephthalate). The compression-resistant container may be a bottle for liquids, including water, drinks, or other packaged liquids. In other embodiments, as described herein, the compression-resistant container may be a thin-walled container for food, such as a clamshell, box, or other protective package for food.

A shape of the wallmay include a set of spheroidal surfaces,,having at least a first spheroidal surfaceand a second spheroidal surface. The shape of the wallmay further include a set of cylindrical surfaces,,having at least a first cylindrical surface. The first cylindrical surfacemay adjoin at least the first spheroidal surfaceand may be positioned between the first spheroidal surfaceand the second spheroidal. The set of spheroidal surfaces,,may also include a third spheroidal surfaceand the set of cylindrical surfaces,,may also include a second cylindrical surface, and a third cylindrical surface. The set of spheroidal surfaces,,and the set of cylindrical surfaces,,may alternate, as shown in.

In some embodiments, the wallmay define a bottle shape. In this embodiment, a shape of the wall may include a set of spheroidal segment shells,,having at least a first spheroidal segment shelland a second spheroidal segment shell. The set of spheroidal segment shells,,may also include a third spheroidal segment shell. Each spheroidal segment shell of the set of spheroidal segment shells may have rotational symmetry around an axis.

The compression-resistant containermay further include a set of cylinder shells,,having at least a first cylinder shell. The set of cylinder shells,,may also include a second cylinder shelland a third cylinder shell. Each cylinder shell of the set of cylinder shells,,may also have rotational symmetry around the axis. As shown, the first cylinder shelland the second cylinder shellmay be positioned between the first spheroidal segment shelland the second spheroidal segment shell. The positioning of the set of spheroidal shells,,relative to the set of cylinder shells,,is described further herein.

The set of spheroidal segment shells,,and the set of cylinder shells,,may define at least a portion of a bodyof the shape of the wall. The wallof the compression-resistant containermay also include a neckand a base.

At least some spheroidal segment shells of the set of spheroidal segment shells,,and the set of cylinder shells,,may be positioned in an alternating pattern along the axis. For example, the second spheroidal segment shelland the third spheroidal segment shellmay alternate with the second cylinder shelland the third cylinder shellalong the axis. As shown, the first spheroidal segment shelland the first cylinder shellmay begin an alternating pattern. However, instead of alternating with another spheroidal segment shell, a larger cylinder shellmay replace the other spheroidal shell that would ordinarily occur in the pattern to provide a label surface between the first cylinder shelland the second cylinder shell.

While the embodiment described herein includes three spheroidal segment shells and three cylinder shells, this is for example purposes only. In application, the set of spheroidal segment shells,,may include more or fewer than three. Likewise, the set of cylinder shells,,may also include more or fewer than three.

Referring to, an embodiment of a compression-resistant container is depicted showing various diameters and angles. A ratio of a semimajor diameter of each of the set of spheroidal segment shells to each of the set of cylinder shells may be between 1.5:1 and 4:1, and more specifically between 1.5:1 and 2:1. As an example, the first spheroidal segment shellmay have a diameterof 65.20 mm, the second spheroidal segment shellmay have a diameterof 63.56 mm, and the third spheroidal segment shellmay have a diameterof 59.99 mm. The first cylinder shellmay have a diameterof 42.21 mm, the second cylinder shellmay have a diameterof 42.21 mm, and the third cylinder shellmay have a diameterof 52.89 mm. Other dimensions are possible.

Each of the set of spheroidal segment shells may have a shell thickness ratio (defined as a ratio of a wall thickness to an outer semimajor radius of each of the set of the spheroidal segment shells) of between 1:500 and 1:200. In some embodiments, the wallmay have a thickness between 0.05 mm and 0.5 mm.

Further referring to, each of the spheroidal segment shells,,, as well as the larger cylinder shell, may adjoin the cylinder shells at a tangential angle. For example, in, a tangential surface angle between the first spheroidal segment shelland the first cylinder shellmay be designated by the angle numbered. A tangential surface angle between the larger cylinder shelland the first cylinder shellmay be designated by the angle numbered. A tangential surface angle between the larger cylinder shelland the second cylinder shellmay be designated by the angle numbered. A tangential surface angle between the second spheroidal segment shelland the second cylinder shellmay be designated by the angle numbered. A tangential surface angle between the second spheroidal segment shelland the third cylinder shellmay be designated by the angle numbered. A tangential surface angle between the third spheroidal segment shelland the third cylinder shellmay be designated by the angle numbered. Finally, a tangential surface angle between the cap portion and the first spheroidal segment shellmay be designated by the angle numbered. In order to resist compression, each of the tangential surface angles,,,,,,between each of the set of spheroidal shells and each of the set of cylinders may be between 30 degrees and 80 degrees.

Other dimensions associated with the compression-resistant containermay affect its compression resistance. As an example, the basemay have a diameter between 4 mm and 1000 mm, and more specifically between 40 mm and 70 mm. The base may have a length between 4 mm and 1000 mm, and more specifically between 40 mm and 70 mm. A total length of the container may be between 20 mm and 2000 mm, and more specifically between 100 mm and 400 mm. The container may have an internal volume between 10 mL and 10 L, and more specifically between 150 mL and 500 mL. The mass of the container may be between 0.05 g and 2 kg, and more specifically between 5 g and 20 g.

Referring to, the mechanical behavior of the embodiments described herein were modeled and a simulation was performed to determine the response to compression forces. Performance was determined using Finite Element Analysis in CAD and was compared to typical bottle designs.

is a table presenting the results of this comparison under a linear elastic explicit dynamics analysis and a non-linear plastic explicit dynamics analysis. Under both the linear and non-linear analysis, the compression-resistant container (for purposes of these results, a bottle) exhibited a higher total force reaction for both a fixed support (not allowing free rotation) and with displacement (allowing movement and rotation) as compared to a typical bottle. As such, overall, the compression resistant container described herein is more compression-resistant than typical containers.

is a stress-strain diagram comparing the pre-yield elastic behavior (linear FEA analysis) of an embodiment of the compression-resistant container (Compression Resistant Container) compared to a typical container (Standard Container).

is a stress-strain diagram comparing the post-yield plasticity behavior (non-linear FEA analysis) of an embodiment of the compression-resistant container (Compression Resistant Container) compared to a typical container (Standard Container).

shows a simulation image for an embodiment of the compression-resistant container described herein. Based on the simulations, it was determined that the design described herein spreads the stress of a 25 lb distributed compressive load across the spheroidal segment shell, and resists flattening. As seen in, the container exhibits an even distribution of force across the spheres, where the greatest amount of stress is contained in the flat portions (e.g., brand label panel) and at the top and base of the container. The shaded regions along the spheres show the least amount of force concentrated along the spheres and cylinders of the body. This is in contrast to a standard container shown in, where stress is concentrated throughout the body.

By making this change to the shape of disposable water bottles, recycling facilities could capture an additional 15% of plastic bottle waste that currently is lost to the paper stream during the separation process. Furthermore, broad implementation by major water bottle corporations would incentivize municipalities to accept plastic water bottles in their curbside recycling programs. It is estimated that widespread acceptance of disposable plastic water bottles in municipal recycling systems would capture an additional 400 million lbs of waste that is sent directly to the landfill every year.

Derivations of this design may be applied to other plastic containers to capture an even higher volume of lost waste, such as the clamshell containers, boxes, and drinking cups that also are flattened and lost at high rates during the sorting process. These containers make up an additional 11% of plastics in the average municipal recycling stream, with a loss rate of 39% that is separated with paper during recycling. The combined impact of design changes across all lightweight plastic containers would have a substantial impact on the recovery of plastics, and in particular PET, and ultimately increase the supply of recycled plastics.

Referring to, an embodiment of a compression-resistant containermay include a bodyhaving a set of spheroidal segmentsand a set of cylinder segments. For clarity and convenience, only three of the spheroidal segmentsare labeled and only four of the cylinder segmentsare labeled. Together, the spheroidal segmentsand the cylinder segmentsmay form a container shape, which may be referred to herein as a box or a clamshell. A topof the bodymay be separable from a bottomof the body, thereby opening the container. Each of the spheroidal segmentsmay have an associated spheroidal surfaceand each of the cylinder segmentsmay have a cylindrical surface. The spheroidal segmentsmay be alternated with the cylinder segments, to provide resistance against compression of the container.

Referring to, a side view of the containeris depicted. The set of spheroidal segments(labeled in) may include a first spheroidal segment, a second spheroidal segment, a third spheroidal segment, and a fourth spheroidal segment. Likewise, the set of cylinder segmentsmay include a first cylinder segment, a second cylinder segment, and a third cylinder segment. The number of spheroidal segments and cylinder segments is for illustrative purposes, and this disclosure contemplates containers having more or fewer segments than illustrated.

The first spheroidal segmentmay have a first spheroidal surface, the second spheroidal segmentmay have a second spheroidal surface, the third spheroidal segmentmay have a third spheroidal surface, and the fourth spheroidal segmentmay have a fourth spheroidal surface. Likewise, the first cylinder segmentmay have a first cylindrical surface, the second cylinder segmentmay have a second cylindrical surface, and the third cylinder segmentmay have a third cylindrical surface. When the containeris opened, the surfaces may be split apart between the topand the bottom.

The first cylindrical surfacemay adjoin at least the first spheroidal surfaceand may be positioned between the first spheroidal surfaceand the second spheroidal surface. The second cylindrical surfacemay adjoin at least the second spheroidal surfaceand may be positioned between the second spheroidal surfaceand the third spheroidal surface. The third cylindrical surfacemay adjoin at least the third spheroidal surfaceand may be positioned between the third spheroidal surfaceand the fourth spheroidal surface. As such, the spheroidal surfaces-and the cylindrical surfaces-may alternate, as shown.

Referring to, an embodiment of a compression-resistant containeris depicted showing radii and angles associated with the spheroidal segments,,,and cylinder segments,,of the container. As an example, the three spheroidal segments on the left (e.g., the spheroidal segments,,) may have a first radius, which may be 32.50 mm, and the spheroidal segment on the right (e.g., the spheroidal segment) may have a second radius, which may be 32.40 mm. A diameterof each of the cylinder segments,,may be 42 mm. A tangential anglebetween each of the spheroidal segments,,,and cylinder segments,,may be 49.75 degrees. The ratio of the radii,to the diametermay increase resistance to compression as compared to shallower angles and the tangential angleis sufficient to provide support during compression while also enabling storage within the container. Other dimensions and advantages are possible.

Referring to, the spheroidal surfaces,,,and the set of cylindrical surfaces,,may define at least a portion of the body(labeled in), which may define a box, a clamshell, or another like container. A hinged opening may be positioned between the topof the body and the bottomof the body as depicted in.

Although various embodiments have been shown and described, the present disclosure is not so limited and will be understood to include all such modifications and variations as would be apparent to one skilled in the art.